Packaging base pad with plastic corners

ABSTRACT

A packaging system for an appliance is provided. The packaging system includes a base pad for supporting an appliance. In preferred embodiments, the system includes pockets for supporting corner posts, and/or corner supports for aiding in the placement and stability of the appliance for use in packaging, stacking, and transporting the appliance.

FIELD OF THE INVENTION

The following description relates generally to a packaging base, and more specifically, to a packaging base with cups or corner supports for aiding in the placement and stability of corner posts used in packaging and transporting appliances.

BACKGROUND OF THE INVENTION

Typically, appliances are enclosed in expanded polystyrene foam for shipping and then shrink-wrapped with clear plastic wrap. Such shrink-wrapped foam packaging protects the appliance during transport, but is not ideal for stacking because the resulting package is not reinforced.

It also is known to seat an appliance on a corrugated bottom tray, and to position paper-wrapped corner posts at the corners of the appliance resting on the corrugated tray. The resulting assembly (with appliance) is then shrink-wrapped with clear plastic wrap. A foam pad typically is adhered to a top surface of the corrugated bottom tray underneath the appliance to provide shock absorption. The corner posts provide structural integrity to the resulting wrapped package to facilitate stacking, while the corrugated bottom tray supports the appliance and facilitates transport thereof, e.g. via a forklift or tow motor. However, the addition of the corrugated bottom tray increases the overall expense of the packaging used for transport, not only from the additional material but also the additional labor required to place and adhere the foam to the corrugated bottom tray.

BRIEF SUMMARY OF THE INVENTION

A packaging system for an appliance is disclosed. The packaging system includes a base pad, a demarcated pocket at a corner of the base pad, and a corner post. The demarcated pocket includes a perimeter wall defining lateral boundaries of the pocket into which a bottom end of the corner post is received.

A further packaging system for an appliance is disclosed. The packaging system includes a base pad, an appliance-corner support, and a corner post. The base pad includes (i) a molded corner region configured to receive the appliance-corner support and (ii) a pocket adjacent to said molded corner region configured to receive a bottom end of the corner post.

A method of manufacturing and storing an appliance is disclosed. The method includes assembling the appliance, along an assembly line therefor, on a base pad that includes a demarcated pocket at a corner of the base pad. The method further includes inserting a corner post into the demarcated pocket, then shrink-wrapping the base pad, the corner post, and the appliance to form a completed packaged assembly, then stacking two or more said completed packaged assemblies, one on top of the other

BRIEF DESCRIPTION OF THE DRAWINGS

Preferred embodiments are disclosed and described in detail herein with reference to the accompanying drawings, wherein:

FIG. 1 is a perspective view of an example base with post cups disposed at its corners;

FIG. 1A is a close-up perspective view of the post cup identified at “1A” in FIG. 1;

FIG. 2 is a close-up perspective view of the aforementioned post cup in FIG. 1 with a corner post supported therein;

FIG. 3 is a perspective view of an example base for supporting an appliance thereon, according to an additional embodiment; and

FIG. 4 is a perspective view of the base of FIG. 3 illustrating corner supports received at its corners and corner posts supported by the corner supports, as disclosed herein.

DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS

Referring first to FIG. 1, a base pad 10 is provided to support an appliance thereon, such as a range or refrigerator, for transport. As seen in FIG. 1, the pad 10 may include features (e.g., ridges, cutouts, elevated or recessed portions, etc.) that correspond to the contours of a bottom of the appliance. In this embodiment, the base pad 10 is made of foam, such as expanded polystyrene. The foam can include molded-in features to provide the aforementioned ridges, cutouts, etc. as known in the art. As seen in FIGS. 1, 1A, and 2, a plurality of corner-post cups 20 are disposed at the corners of the foam base pad 10. Each cup 20 provides a demarcated pocket that is dimensioned to receive and accommodate therein a bottom end of a corner post 30, such as a paper-wrapped corner post as known in the art. By providing a demarcated pocket, the cup 20 aids in the placement of the corner post 30 (e.g., by automated/robotic placement of the corner post 30 into the cup 20). Once inserted within the cup 20, the corner post 30 is secured to the pad 10 and against lateral movement or displacement of its proximal end (inserted in the cup 20) by virtue of the demarcated pocket alone. In this manner, the post 30 is held in-place at the corner of the package prior to and during wrapping with plastic wrap. Thus the corner post 30 is retained in position securely at the corners of the pad 10 and adjacent the corners of the appliance resting thereon throughout the packaging and shipping process of the appliance.

In the embodiment of FIG. 1, the cups 20 are adhered to the pad 10 in complementary-shaped corner recesses thereof. As seen in FIGS. 1, 1A, and 2, when the cup 20 is L-shaped, the pad 10 includes a corresponding L-shaped recess at a corner position to receive the cup 20. As seen in FIG. 1A, each cup 20 includes a bottom surface 21 and a perimeter wall 22 that extends upward and around the perimeter of the demarcated pocket of cup 20, thus defining the lateral boundary and shape of the pocket. The perimeter wall 22 may be substantially continuous about (and thus define) the entire perimeter of the pocket as-shown. Or it may be discontinuous or interrupted, so long as the perimeter wall 22 defines a sufficient boundary (or boundaries) to retain the bottom end of a corner post 30 once inserted therein, which is effective to prevent lateral movement in all directions of the post 30 out from the pocket. Each cup 20 also can include one or more projections 23 that extend inward from the perimeter wall 22. The projections 23 are sized and positioned to contact or engage within a side-wall recess of the corner post 30 placed when received in the cup 20 (as seen in FIG. 2), thus providing an additional locating element to ensure proper positioning and insertion of the corner post 30 within the cup 20. For example, the projections 23 and associated side-wall recesses in the corner post 30 can act as a key/key-way that help facilitate proper alignment upon automated insertion of the corner post 30 via a robotic effector.

In one embodiment, the cups 20 are adhered to the foam pad 10 with an adhesive after the pad 10 has been formed. For example, the pad 10 may be molded and cured, e.g. to yield a shaped block of expanded polystyrene in a conventional manner, which includes L-shaped corner recesses configured to support L-shaped cups 20. In a next step, the L-shaped cups 20 are adhered to the pad 10 within those L-shaped corner recess using an adhesive. Alternatively, the pad 10 can be molded directly and adhered to the cups at its corner positions as-formed. For example, the cups 20 can be mold inserts in a mold cavity for forming the foam pad 10. Then the foam percursor (e.g. prepolymer) can be injected into the mold cavity, where it will flow around and the cups 20 and thereafter be cured to form the finished foam pad. The resulting integrated pad assembly composed of the cured foam pad 10 with molded-in cups 20 can be de-molded once the curing process is complete.

Once formed, the pad assembly (i.e. pad 10 and cups 20) is able to support an appliance during assembly, packaging, and/or transport. For example, the pad assembly can be utilized from the beginning of the manufacturing process, wherein the appliance actually is assembled, in whole or in part, on the foam pad 10 as it travels along the appliance assembly line. Once appliance assembly is completed on the pad assembly, the corner posts 30 are inserted into the cups 20. In one embodiment, the pad assembly, the corner posts 30, and the appliance are then shrink-wrapped with clear plastic wrap to yield a completed appliance package ready for transport.

In another embodiment, a corrugated pad is placed on the upper ends of the corner posts 30. The corrugated pad may be adhered to the corner posts 30 via an adhesive. Thereafter, the entire assembly (lower pad, corrugated pad, four corner posts extending between the corrugated pad and cups 20 in the lower pad, and the appliance within) is shrink-wrapped for transport. In still another embodiment, a second pad assembly is fitted over the top of the appliance prior to shrink-wrapping, to receive and fix the positions of the upper ends of the corner posts 30. Thereafter, the entire assembly (upper and lower pad assemblies, four corner posts extending between opposing cups 20 in the upper and lower pad assemblies and the appliance within) is shrink-wrapped for transport. In all embodiments (i.e. with and without the upper pad assembly or with the upper corrugated pad), the resulting package is sufficiently reinforced via the pad 10, cups 20, and corner posts 30 that the packaged appliance can be readily stacked two high, preferably at least four high or five high. The bottom surfaces 21 in the cups 20 provide bottom-side reinforcement to support the bottom ends of the corner posts 30 such that they are not forced to penetrate downward, out from the associated wrapped package, e.g. from weight resting thereon from above. Moreover, when both top and bottom pad assemblies are used, the bottom pad assembly of one package rests on the preferably planar upper surface of the top pad assembly of the subjacent package, thus adding additional robustness and stacking stability, which may enable even higher orders of stacking, such as six or seven high.

When used, the top pad assembly can be configured similar to, e.g. as a mirror image of, the bottom pad assembly of the same package, except that preferably the top pad assembly has a series of recesses, ridges and/or other features that will render it complementary to the top part of the appliance of which it will be installed.

In one embodiment, the pad 10 is made of expanded polystyrene foam as noted above, or it can be made of expanded polypropylene foam. In another embodiment, the pad 10 is made of injection molded plastic. Other conventional foamed and solid plastics also can be used.

In one embodiment, the cup 20 is made of a strong plastic material, such as high-density polyethylene. Alternatively, other conventional plastic materials also may be used.

In a second embodiment illustrated in FIGS. 3 and 4, the base pad 10 a is formed as a molded plastic frame; for example a ladder frame dimensioned to correspond to the overall plan-view outer dimension of the appliance that will be supported on the pad 10 a. In this embodiment, the molded plastic frame is not made of foam as before, but is a solid, substantially non-porous and structurally rigid plastic, such as high-density polyethylene. The molded plastic base pad 10 a includes integrally formed, demarcated corner pockets 60 dimensioned to accommodate and receive the bottom ends of corner posts 30 as in the prior embodiment. That is, in this embodiment the corner pockets 60 are defined by perimeter walls that are formed with and as part of the plastic-frame base pad 10 a. The corner pockets 60 can be configured similarly as and have features similar to the cup 20 defining the demarcated pockets as described in the preceding embodiment.

The base pad 10 a also includes integrally formed molded corner regions 50 that are dimensioned to receive and secure in-place against lateral movement respective appliance-corner supports 70, inward of the corner pockets 60. The molded corner regions 50 provide or constitute in-molded features in the corner region of the plastic-frame base pad 10 a that demarcate and fix locations for installation of the appliance-corner supports 70, preferably via complementary features on the underside of the respective appliance-corner supports 70. In this manner, the molded corner regions 50 maintain the lateral positions of the respective supports 70 via only gravity, without requiring any adhesive or fasteners between the supports 70 and the pad 10 a. The pad 10 a and appliance-corner supports 70 (when installed thereon) are configured to support the appliance thereon, such that the appliance rests at its four corners on the appliance-corner supports 70, which in-turn rest on corner portions of the pad 10 a received in the respective molded corner regions 50. As in the prior embodiment, again here the appliance can be assembled atop the resulting pad assembly (pad 10 a and corner supports 70), which travels down an assembly line for the appliance, prior to packaging and shipping.

As seen in FIG. 4, the appliance-corner supports 70 include features that correspond to and complementarily receive bottom features of the appliance. For example, the appliance-corner supports 70 may include recesses that are dimensioned to receive adjustable feet on the bottom of the appliance.

To assemble a completed, reinforced package, corner posts 30 are positioned in the pockets 60 integrated in the pad 10 a, adjacent to the appliance-corner supports 70 in order to provide additional structural support to the appliance during packaging and transport.

Similarly as in the preceding embodiment, each pocket 60 includes a perimeter wall 61 that defines the perimeter of the pocket 60. The wall 61 may be substantially continuous as illustrated, or again it may be interrupted or discontinuous so long as it restrains lateral movement of the bottom end of a corner post 30 inserted in the associated pocket 60. Each pocket further can include one or more projections 62 that extend inward from the perimeter wall 61. The projections 62 are sized and positioned as in the preceding embodiment, to interact with (e.g. to position and be received within) side-wall features in the corner post 30 that facilitate proper alignment and insertion thereof within the pocket 60, for reasons already explained.

Once appliance assembly is completed with the appliance in place and resting on the base assembly (i.e. base 10 a and corner supports 70), the corner posts 30 are inserted into the pockets 60. The base assembly, corner posts 30, and appliance then can be shrink-wrapped for transport. Alternatively, and similarly as above, a second base assembly (i.e. base 10 a and corner supports 70) can be fitted over the top of the appliance to receive and fix the positions of the upper ends of the corner posts 30. Thereafter, the entire assembly can be shrink-wrapped. The resulting package is sufficiently reinforced via the corner posts 30 that the packaged appliances can be readily and safely stacked, while the base with the appliance-corner supports 70 therein can support the appliance during both assembly on the line and subsequent shipping and storing.

In one embodiment, the base 10 a is molded from a strong plastic material, such as high-density polyethylene as noted above. But other plastic materials can be used.

The appliance-corner supports 70 can be molded from foam, such as expanded polystyrene or expanded polypropylene. Thus, in this embodiment the corner supports 70 provide cushioning for the appliance when the completed, wrapped package is transported, whereas the base pad 10 a provides only structural support and little to no cushioning. In another embodiment, the appliance-corner supports 70 are made of injection molded plastic, which likley will provide less effective cushioning of the appliance during transport.

Illustrative embodiments have been described, hereinabove. It will be apparent to those skilled in the art that the above apparatuses and methods may incorporate changes and modifications without departing from the scope of this disclosure. The invention is therefore not limited to particular details of this disclosure except to the extent that the following claims are necessarily so limited. 

What is claimed is:
 1. A packaging system for an appliance, the system comprising a base pad, a demarcated pocket at a corner of the base pad, and a corner post, the demarcated pocket comprising a perimeter wall defining lateral boundaries of the pocket into which a bottom end of the corner post is received.
 2. The packaging system of claim 1, wherein the demarcated pocket is adhered to the base pad.
 3. The packaging system of claim 1, wherein the demarcated pocket is integrally formed in the base pad.
 4. The packaging system of claim 1, the demarcated pocket further comprising a projection that extends inward from the perimeter wall, the projection being configured to aid in alignment of the bottom end of the corner post within the pocket.
 5. The packaging system of claim 1, said perimeter wall being a substantially continuous wall about said pocket.
 6. The packaging system of claim 2, wherein the demarcated pocket is provided as a cup that is used as a mold insert to which the base pad is molded and formed.
 7. The packaging system of claim 6, the base pad being made of expanded polystyrene.
 8. The packaging system of claim 6, the cup being made of high-density polyethylene.
 9. The packaging system of claim 6, the corner of the base pad comprising a recess that has a complementary shape to an exterior surface of the cup.
 10. A packaging system for an appliance, the system comprising a base pad, an appliance-corner support, and a corner post, the base pad comprising: (i) a molded corner region configured to receive the appliance-corner support and (ii) a pocket adjacent to said molded corner region configured to receive a bottom end of the corner post.
 11. The packaging system of claim 10, the pocket being defined by a substantially continuous perimeter wall that extends around a perimeter of the pocket.
 12. The packaging system of claim 11, the pocket further comprising a projection that extends inward from the perimeter wall, the projection being configured to aid in alignment of the bottom end of the corner post within the pocket.
 13. The packaging system of claim 10, the base pad being made of high-density polyethylene.
 14. The packaging system of claim 10, the appliance-corner support being made of expanded polystyrene or expanded polypropylene.
 15. The packaging system of claim 10, the appliance-corner support being made of injection molded plastic.
 16. A method of manufacturing and storing an appliance, comprising assembling the appliance, along an assembly line therefor, on a base pad comprising a demarcated pocket at a corner of the base pad, and inserting a corner post into the demarcated pocket, then shrink-wrapping the base pad, the corner post, and the appliance to form a completed packaged assembly, then stacking two or more said completed packaged assemblies, one on top of the other. 